Pleated Nonwoven Filter Media Without Metal Mesh Support
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Solution Overview
Problem
Conventional air filters face challenges with high pressure drop, reduced air flow, and low dust loading capacity due to the use of metal mesh-backed pleated filters, limiting their application and environmental sustainability.
Innovation Solution
A nonwoven material with a first fiber layer and a second layer of filaments providing support, allowing the filter to maintain shape without a metal mesh, enhancing air flow and dust holding capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If metal mesh is used to support pleated filter structure, then filter structural stability is improved, but pressure drop increases and air flow is reduced
Solution Approach 1:
The patent removes the metal mesh component from the filter structure entirely, replacing it with a self-supporting pleated media design. The pleated media itself provides structural stability through its folded geometry and material properties, eliminating the need for a separate support mesh that would otherwise increase pressure drop and reduce air flow.
Solution Approach 2:
The patent introduces a adhesive or bonding mechanism as an intermediary to secure the pleated media to the filter frame, replacing the mechanical support function previously provided by metal mesh. This bonding approach maintains structural stability without requiring a continuous mesh that would obstruct air flow.
2Stability of the object's composition
If metal mesh is used to support pleated filter structure, then filter structural stability is improved, but environmental sustainability deteriorates
Solution Approach 1:
The patent extracts and removes the metal mesh component from the filter assembly, eliminating the environmental harm associated with metal production, disposal, and incineration. The entire filter becomes incinerable or recyclable depending on the media material used.
Solution Approach 2:
The patent enables the filter to be fully discarded through incineration or recycling without requiring separation of metal components. The pleated media can be completely processed as waste or recovered material, eliminating the need to remove and separately dispose of metal mesh.
3Reliability
If conventional pleated filter media is used, then particle capture efficiency is achieved, but dust loading capacity is limited
Solution Approach 1:
The patent transitions from a flat filter media configuration to a three-dimensional pleated structure, increasing the surface area available for particle capture and dust storage. This dimensional change allows the filter to handle higher dust loads while maintaining capture efficiency.
Solution Approach 2:
The patent employs composite pleated media structures that combine different fiber materials or pore size distributions to optimize both particle capture efficiency and dust holding capacity. The composite structure allows simultaneous achievement of fine particle filtration and high dust loading tolerance.
Data Source
AI summary
Nonwoven material, pleated filter media and filters, such as residential and commercial air filters, are provided. A nonwoven material comprises a first fiber layer and a second layer in contact with the first fiber layer. The second layer comprises two or more rows of filaments spaced from each other and extending along at least a portion of the first layer. The rows of filaments provide sufficient support to the filter media that it is capable of holding its shape over time. Thus, a filter media comprising the nonwoven material may be manufactured without a metal mesh, which improves the safety of the filter during handling and facilitates its incineration at the end of its life. In addition, the overall filter may have a lower pressure loss and a higher dust holding capacity because there it does not contain a metal mesh layer blocking air flow through the filter.